TURBOCHARGER (for DPF) REMOVAL


  1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.

  2. REMOVE FRONT EXHAUST PIPE ASSEMBLY

    Click here

  3. REMOVE INTERCOOLER ASSEMBLY

    Click here

  4. REMOVE NO. 1 ENGINE UNDER COVER

  5. REMOVE NO. 2 ENGINE UNDER COVER

  6. DRAIN ENGINE COOLANT

    CAUTION:

    Do not remove the radiator reservoir cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.


    1. Loosen the radiator drain cock plug.

      Tech Tips

      Collect the coolant in a container and dispose of it according to the regulations in your area.

    2. A01DY58E01

      Drain the coolant by removing the reservoir cap and, using a wrench, remove the vent plug.

    3. Loosen the cylinder block drain cock plug.

      A01E07NE01

  7. REMOVE FRONT FENDER APRON SEAL UPPER


    1. Remove the 5 clips and front fender apron seal upper.

  8. REMOVE FRONT FENDER SEAL


    1. Remove the 5 clips and front fender seal.

  9. REMOVE AIR CLEANER ASSEMBLY


    1. A01E1IB

      Detach the wire harness clamp and disconnect the mass air flow meter connector.

    2. Loosen the hose clamp and disconnect No. 1 air cleaner hose from the compressor inlet elbow.

    3. Remove the 2 bolts and air cleaner assembly together with the No. 1 air cleaner hose.

  10. REMOVE VENTILATION PIPE


    1. A01DXEZ

      for Cold Area Specification Vehicles:

      Disconnect the No.12 water by-pass hose and No. 13 water by-pass hose.

    2. A01DXQXE01
      Text in Illustration
      *A except Cold Area Specification Vehicles
      *B for Cold Area Specification Vehicles

      Remove the bolt and ventilation pipe.

  11. REMOVE COMPRESSOR INLET ELBOW


    1. A01E1Y7

      Disconnect the 2 connectors and detach the wire harness clamp.

    2. A01E14V

      Disconnect the No. 1 turbo water hose.

    3. Disconnect the No. 2 water by-pass hose.

      A01DXHFE01
      Text in Illustration
      *A except Cold Area Specification Vehicles *B for Cold Area Specification Vehicles
      *1 No. 2 Water By-pass Hose *2 No. 9 Water By-pass Hose
      *3 No. 13 Water By-pass Hose - -

    4. except Cold Area Specification Vehicles:

      Disconnect the No. 9 water by-pass hose.

    5. for Cold Area Specification Vehicles:

      Remove the No. 13 water by-pass hose.

    6. Remove the 2 nuts, compressor inlet elbow and gasket.

    7. A01E0UQE01
      Text in Illustration
      *A except Cold Area Specification Vehicles
      *B for Cold Area Specification Vehicles
      *1 No. 7 Water By-pass Hose
      *2 No. 9 Water By-pass Hose
      *3 No. 12 Water By-pass Hose

      Remove the No. 7 water by-pass hose.

    8. except Cold Area Specification Vehicles:

      Remove the No. 9 water by-pass hose.

    9. for Cold Area Specification Vehicles:

      Remove the No. 12 water by-pass hose.

  12. REMOVE NO. 1 TURBO INSULATOR


    1. A01E0PK

      Remove the 2 bolts and No. 1 turbo insulator.

  13. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR


    1. A01DYZA

      Remove the bolt and No. 1 exhaust manifold heat insulator.

  14. REMOVE NO. 2 EXHAUST MANIFOLD HEAT INSULATOR


    1. A01E241

      Remove the 2 bolts and No. 2 exhaust manifold heat insulator.

  15. REMOVE NO. 3 EXHAUST MANIFOLD HEAT INSULATOR


    1. A01E06P

      Remove the 2 bolts and No. 3 exhaust manifold heat insulator.

  16. REMOVE TURBINE OUTLET ELBOW STAY


    1. A01DYUF

      Detach the wire harness clamp and remove the bolt, nut and turbine outlet elbow stay.

  17. REMOVE NO. 2 TURBINE OUTLET ELBOW


    1. A01DX6C

      Remove the 3 nuts, No. 2 turbine outlet elbow and gasket.

  18. DISCONNECT NO. 1 FUEL PIPE


    1. A01DVRE

      Detach the hose clamp and disconnect the No. 4 turbo water hose from the No. 4 water by-pass pipe.

    2. Disconnect the exhaust fuel addition injector connector.

    3. Remove the union bolt and gasket from the No. 1 fuel pipe.

    4. Disconnect the No. 1 fuel pipe from the turbine outlet elbow.

  19. REMOVE TURBINE OUTLET ELBOW


    1. Disconnect the No. 3 turbo water hose from the No. 3 water by-pass pipe.

    2. Remove the 3 nuts, turbine outlet elbow and gasket.

      A01DYRXE01
      Text in Illustration
      *1 Gasket *2 Union Bolt
      *3 No. 3 Water By-pass Pipe *4 No. 4 Water By-pass Pipe
      *5 No. 3 Turbo Water Hose *6 Turbine Outlet Elbow

    3. Remove the bolt, union bolt, gasket and No. 3 water by-pass pipe from the turbine outlet elbow.

    4. Remove the union bolt, gasket and No. 4 water by-pass pipe from the turbine outlet elbow.

  20. REMOVE TURBOCHARGER STAY


    1. A01E1LJ

      Remove the 2 bolts, nut and turbocharger stay.

  21. REMOVE TURBO OIL INLET PIPE SUB-ASSEMBLY


    1. A01DXE2E03

      Remove the 2 bolts, 2 nuts, union bolt, turbo oil inlet pipe sub-assembly and 3 gaskets.

      Note

      Do not loosen the nut labeled A in the illustration.

  22. REMOVE TURBOCHARGER SUB-ASSEMBLY


    1. A01DWFQ

      Remove the 3 nuts, turbocharger sub-assembly and gasket.

  23. REMOVE NO. 1 TURBO WATER PIPE SUB-ASSEMBLY


    1. Remove the No. 1 turbo water hose and No. 3 turbo water hose.

    2. A01DYC0

      Remove the 2 nuts, bolt, No. 1 turbo water pipe sub-assembly and gasket.